Attachment III - Technical Information
OVERVIEWBefore delivering any of the vehicles involved in this program, dealers are to replace or modify the headliner for wrinkles based upon the following criteria:
^ For vehicles built on or before October 10, 2012, the headliner must be replaced.
^ For vehicles built on or after October 11, 2012, dealers must inspect the headliner for the presence of wrinkles around the moon roof opening to determine if the headliner must be modified or replaced.
INSPECTION
For vehicles built on or after October 11, 2012, dealers must inspect the headliner for the presence of wrinkles around the moon roof opening to determine if the headliner must be modified or replaced. See Figure 1.
^ If wrinkles are present, the headliner must be replaced.
^ If wrinkles are not present, the headliner must be modified to prevent wrinkles from occurring in the future. The modification involves lowering the headliner and cutting reliefs into the blocks and supports glued to the backside of the headliner. The reliefs allow the components to expand and contract and at different rates without wrinkling the headliner material.
SERVICE PROCEDURE
Removal
Vehicles Equipped with Rain Sensitive Wipers and/or Auto Dimming Mirror
1. Remove the glove compartment. For additional information, refer to Workshop Manual (WSM) Section 501-12.
2. Disconnect the rain sensor and/or auto dimming mirror electrical connectors. See Figure 2.
NOTE:
Rain sensor electrical connector shown, auto dimming mirror electrical connector similar.
All Vehicles
3. NOTE: If the vehicle is equipped with rain sensitive wipers and/or auto dimming mirror the RH Instrument Panel (IP) side trim panel will have been removed previously.
Remove the RH and LH IP side trim panels. See Figure 3.
NOTE:
RH side shown, LH side similar.
4. Remove the RH and LH lower A-pillar trim panels. See Figure 4.
NOTE:
RH side shown, LH side similar.
5. Remove the upper RH and LH A-pillar trim panels. See Figure 5.
NOTE:
RH side shown, LH side similar.
6. Disconnect the headliner wire harness to body retainers along the LH A-pillar. See Figure 6a. If equipped, disconnect the rain sensor and/or auto dimming mirror wire harness to body retainers from the RH A-pillar. See Figure 6b.
NOTE:
Note the position of the vehicle's seats, so that they can be returned to the customers original position once the repair is complete.
7. Position the RH and LH front seats to their full forward position.
8. Remove the RH and LH front and rear door opening sill plates.
9. Remove the RH and LH lower B-pillar trim panels.
10. Remove the safety belt D-ring cover and bolt from the RH and LH upper B-pillar. See Figure 7. Position the safety belts away from the upper B-pillars.
NOTE:
RH side shown, LH side similar.
11. Remove the bolts and the RH and LH upper B-pillar trim panels. See Figure 8.
NOTE:
RH side shown, LH side similar.
12. Position the RH and LH rear seat backrests down.
13. Position the safety belt away from the RH and LH lower C-pillar trim panels. Starting from the top, pull to release the clips and remove the RH and LH lower C-pillar trim panels.
NOTICE:
Do not separate the RH and LH D-pillar trim panels from the upper C-pillar trim panels. They should be removed as an assembly to prevent damage to the retaining clips.
14. Remove the RH and LH upper C-pillar and D-pillar trim panels together. See Figure 9.
a. Position the safety belt out of the opening in the RH and LH upper C-pillar trim panels.
b. Remove the RH and LH upper C-pillar and D-pillar trim panels by pulling to release the retaining clips.
NOTE:
RH side shown, LH side similar.
15. Position the RH and LH rear seat backrests up, and then the RH and LH front seats to the full rearward and reclined position.
NOTE:
Steps 16-24 are only required if the headliner is being removed for replacement. If replacement is not required, skip to step 25 on Page 10.
16. Remove the Body Control Module (BCM). For additional information, refer to WSM Section 419-10.
17. Position aside the BCM mounting bracket by removing the three bracket nuts. Only position aside far enough to access the electrical connector behind the bracket. See Figure 10.
18. Disconnect the headliner electrical connector (closest to the LH front door opening) behind the BCM mounting bracket. See Figure 11.
19. Remove the floor console. For additional information, refer to WSM Section 501-12.
Vehicles With Manual Transmission
20. Remove the shift cables from the gearshift lever. See Figure 12.
21. Remove the four bolts and the gearshift lever. See Figure 13.
Vehicles With Automatic Transmission
22. Disconnect the selector lever cable end from the selector lever. See Figure 14.
23. Remove the bolt from the selector lever cable retaining bracket. Remove the bracket and position the selector lever cable aside. See Figure 15.
24. Disconnect the selector lever electrical connector. Remove the four bolts and remove the selector lever. See Figure 16.
All Vehicles
25. If equipped, remove the rear view mirror trim. See Figure 17.
26. If equipped, disconnect the rain sensor and/or auto dimming mirror electrical connectors behind the rear view mirror.
27. Remove the RH and LH sunshade from the vehicle.
^ Remove the clip cover and remove the clip. Disconnect the electrical connector from the RH and LH sunshades.
28. Remove the RH and LH sunshade hooks.
^ Remove the screw from each hook and remove the RH and LH hooks.
29. Remove the four assist handles.
^ Using a small non-marring plastic trim tool, expose the fasteners by removing the fastener covers. Remove the fasteners from each handle and remove all handles.
30. Lower the headliner by pulling downward to release the nine magnets and two guide pins. If headliner replacement is not required, proceed to "Headliner Modification Procedure".
Headliner Replacement
1. With the help of an assistant, remove the headliner through the front passenger side door. See Figure 18.
2. NOTICE: Special care needs to be taken while removing the overhead console. The rear attachment retaining tabs are extremely fragile. See Figure 19a and 19b.
Remove the overhead console from the headliner. See Figure 19a and 19b (headliner cutaway view shown for clarity).
a. Disengage the rear overhead console attachments by pushing up on the console from the interior side while holding the headliner bracket in place. Slowly press the retaining tab inboard to release.
b. Support the overhead console from the interior side and use a set of pliers to release the middle retaining tabs.
c. Pry down gently to free the overhead console. Rotate the rear of the console downward to access the electrical connectors.
d. Disconnect and remove the overhead console.
NOTE:
The 3M(TM) Super-Fast Repair Adhesive (04747) will set in 20 seconds. Continually make sure that the wire harness is routed correctly when applying adhesive. The use of masking tape to temporarily hold the harness in position while applying the adhesive will aid in proper installation of the wire harness.
3. Transfer the wire harness in the following sequence:
a. Using a suitable marking tool, mark the new headliner with the routing and exit points of the wire harness from the original headliner.
b. Carefully remove the wire harness from the original headliner.
c. Position the wire harness onto the new headliner and check that the harness has enough length to make all connections.
d. Apply the 3M(TM) Super-Fast Repair Adhesive (04747) in the same location as the factory installed adhesive along the full length of the wire harness-to-headliner.
4. Transfer the rear interior lamp, Radio Transceiver Module (RTM) and brackets to the new headliner. See Figure 20.
5. Install the overhead console into the new headliner:
a. Connect the overhead console electrical connectors.
b. Insert the front portion of the overhead console first and then bring the rear of the console flush with the headliner.
c. Push evenly on both sides of the console to engage the console clips. Engage the middle console clips, followed by the front clips, and lastly the rear clips.
Headliner Modification Procedure
NOTE:
Modification of the headliner reinforcements will prevent wrinkles by allowing greater flexibility of the substrate material.
1. Mark cut locations on the headliner reinforcement material. See Figure 21.
NOTICE:
When cutting headliner reinforcements, care must be taken not to cut any deeper than the reinforcement material. Cutting deeper than the reinforcement material can result in damage to the headliner. Holding the DREMEL(R) cutting tool at a 45 degree angle will help ensure a smoother cut and reduce the risk of cutting deeper than necessary.
2. Using a DREMEL(R) tool with bit (part # 9903), cut the plastic reinforcements following the previously marked locations. See Figure 22.
3. Using a shop vacuum, clean the vehicle of any debris created during headliner modification.
Headliner Installation
NOTE:
Step 1 is only required if the headliner has been removed for replacement.
1. With the help of an assistant, install the headliner through the front passenger side door. See Figure 18.
2. Raise the headliner and engage the nine magnets and two guide pins.
3. Install all four assist handles.
4. Install the RH and LH sunshade hooks.
^ Tighten fasteners.
5. Install the RH and LH sunshades.
^ Connect the electrical connector. Install the clip and clip cover.
6. If equipped, connect the rain sensor and/or auto dimming mirror electrical connectors behind the rear view mirror.
7. If equipped, install the rear view mirror trim. See Figure 17.
NOTE:
Steps 8-16 are only required if the headliner has been removed for replacement. If replacement was not required, proceed to Step 17.
Vehicles With Automatic Transmission
8. Install the selector lever and tighten the four bolts. Connect the selector lever electrical connector. See Figure 16.
^ Tighten selector lever bolts to 9 Nm (80 lb-in).
9. Reposition the selector lever cable and install the retaining bracket. See Figure 15.
^ Tighten cable retaining bracket bolt to 7 Nm (62 lb-in).
10. Connect the selector lever cable end from the selector lever. See Figure 14.
Vehicles With Manual Transmission
11. Install the gearshift lever and tighten the four bolts. See Figure 13. Tighten gearshift lever bolts to 9 Nm (80 lb-in).
12. Install the shift cables onto the gearshift lever. See Figure 12.
All Vehicles
13. Install the floor console. For additional information, refer to WSM Section 501-12.
14. Connect the headliner electrical connector behind the BCM mounting bracket location. See Figure 11.
15. Reposition the BCM mounting bracket. Install and tighten the three bracket nuts. See Figure 10.
16. Install the Body Control Module (BCM). For additional information, refer to WSM Section 419-10.
17. Position the RH and LH front seats to the full forward and upright position, and position the RH and LH rear seat backrests downward.
18. Install the RH and LH upper C-pillar and D-pillar trim panels. See Figure 9.
^ Reposition the safety belts into the opening in the C-pillar upper trim panels.
19. Install the RH and LH lower C-pillar trim panels and engage the clips.
^ Reposition the safety belts back to the lower C-pillar trim panels.
20. Position the RH and LH rear seat backrests up.
21. Install the RH and LH upper B-pillar trim panels and install the bolts. See Figure 8.
^ Tighten upper B-pillar trim panel bolts to 9 Nm (80 lb-in).
22. Reposition the RH and LH safety belts to the upper B-pillars and install the D-ring bolts. See Figure 7.
^ Tighten D-ring bolts to 40 Nm (30 lb-ft) and install the safety belt D-ring covers.
23. Install the RH and LH lower B-pillar trim panels.
24. Install the RH and LH front and rear door opening sill plates.
25. Connect the wire harness to body retainers along the LH A-pillar. See Figure 6a. If equipped, connect the rain sensor and/or auto dimming mirror wire harness to body retainers to the RH A-pillar. See Figure 6b.
26. Install the RH and LH upper A-pillar trim panel. See Figure 5.
27. Install the RH and LH lower A-pillar trim panel. See Figure 4.
28. NOTE: Vehicles equipped with rain sensitive wipers and/or auto dimming mirror should only install the LH instrument panel side panel at this time. The RH panel will be installed during glove compartment installation.
Install the RH and LH IP side panels. See Figure 3.
Vehicles Equipped with Rain Sensitive Wipers and/or Auto Dimming Mirror
29. Connect the rain sensor and/or auto dimming mirror electrical connectors. See Figure 2.
30. Install the glove compartment. For additional information, refer to WSM Section 501-12.
31. Position the vehicle seats back to the customers original position.
32. Return the vehicle to the customer.